| | Test results |
| 0 | PRELIMINARY CHECKS | All OK | Problems encountered | Operation |
|---|
| Check that the air intake/vacuum circuit is working properly, checking for any blocked ducts. Check for leaks from the intake manifolds after the compressor. Check for any fuel leaks from the pipes. | Move on to Step 1. | 1. Leaks from the air intake circuit.2. Fuel leaks from the pipes. | 1. Restore the seal on the air intake system.2. Restore the seal for the pipes. |
| 1 | Checks using diagnostic equipment | All OK | Problems encountered | Operation |
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| Check that there are no errors by connecting to the engine management control unit using the Examiner. | Move on to Step 2. | Incorrect parameters. | Restore the correct parameters. |
| 2 | Accelerator pedal check | All OK | Problems encountered | Operation |
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| Check that the accelerator pedal sensor is working properly, by connecting to the engine management control unit using the Examiner. | Move on to Step 3. | Sensor defective. | Replace the accelerator pedal. Op. 1068A20 ACCELERATOR PEDAL WITH BUILT-IN POTENTIOMETER - R.R |
| 3 | EGR valve check | All OK | Problems encountered | Operation |
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| Check that the EGR valve is not stuck open. | Move on to Step 4. | Valve stuck open. | Replace EGR valve. |
| 4 | Turbocharger adjustment check | All OK | Problems encountered | Operation |
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| Using the diagnostic equipment, carry out the active diagnosis for the turbocharger regulating solenoidCheck the operation of the turbo pressure control solenoid valve. Check the operation of the variable geometry control actuator. See Test 1064BC VARIABLE GEOMETRY TURBOCHARGER ACTUATOR LEAKAGE TESTCheck the maximum turbocharger supercharging pressure. See Test 1064BA TURBOCHARGING PRESSURE CHECK | Move on to Step 5. | 1. Solenoid valve not working.2. Fuse blown3. Actuator not working properly.4. Vacuum circuit defective.5. Turbocharger defective. | 1. Restore the wiring continuity. See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT Replace the solenoid if necessary. Op. 1064B42 SOLENOID CONTROLLING TURBOCHARGER VANE POSITION ACTUATOR - R.R 2. Replace the fuse after having identified what caused it to blow.3. Replace the turbocharger. Op. 1064A11 TURBOCHARGER WITH CATALYTIC CONVERTER - R.R. 4. Check the condition of the vacuum circuit; if necessary, replace the damaged components. |
| 5 | Brake pedal switch check | All OK | Problems encountered | Operation |
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| Check that the brake pedal switch is working properly. | Move on to Step 6. | 1. Brake pedal does not return.2. Switch stuck closed.3. Wiring short circuited. | Eliminate the cause of the sticking.Replace the switch.Restore the correct connection. See E2021 BRAKE LIGHTS |
| 6 | Injector seal check | All OK | Problems encountered | Operation |
|---|
| Check for any leaks from the injectors. See Test 1060OC INJECTOR SEAL TEST | Move on to Step 7. | Injectors defective. | Replace the injectors. Op. 1060F10 FUEL INJECTORS - R.R. |
| 7 | Flow meter check | All OK | Problems encountered | Operation |
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| Check that the flow meter is working properly - flow meter signal too low - (to prevent the formation of black smoke). See Test 1060GS FLOW METER OPERATION CHECK | Move on to Step 8. | Flow meter defective. | Replace the flow meter. Op. 1060G10 AIR FLOW METER - R.R. |
| 8 | High pressure check | All OK | Problems encountered | Operation |
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| Connect the diagnostic equipment to the diagnostic socket.Check, as described, See Test 1060OD HIGH PRESSURE FUEL CIRCUIT CHECKthat the diesel pressure parameter is correct | Move on to Step 14. | Pressure not correct. | Move on to Step 9. |
| 9 | Low return pressure check | All OK | Problems encountered | Operation |
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| Check See Test 1060OA LOW FUEL RETURN PRESSURE CIRCUIT CHECKthat the pressure in the return pipe to the tank is less than 1 bar. | Move on to Step 10. | Pressure above the maximum limit: return pipe to the tank obstructed. | Repair the pipe and replace if necessary. |
| 10 | Low supply pressure check | All OK | Problems encountered | Operation |
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| Check See Test 1060OB LOW FUEL DELIVERY PRESSURE CIRCUIT CHECKthat the diesel pressure between the filter and the pressure pump is between 4.5 and 6 bar. | Move on to Step 11. | Pressure not correct. | Move on to Step 12. |
| 11 | Low supply pressure check | All OK | Problems encountered | Operation |
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| Check that the difference in pressure upstream and downstream of the filter is less than 1 bar. | Move on to Step 12. | Difference in pressure more than 1 bar. | Replace the fuel filter cartridge. Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE |
| 12 | Check on operation of low pressure supply pump | All OK | Problems encountered | Operation |
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| Check that the pump supply voltage is equal to 12V and that the current uptake is between 2 and 10 A. | Move on to Step 13. | 1. Voltage lower than 12 V.2. Current greater than 10 A: pump defective.3. Current less than 2 A: pump obstructed. | 1. Check electrical wiring. See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT 2. Replace the fuel pump. Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GAUGE CONTROL - R + R 3. Replace the fuel pump Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GAUGE CONTROL - R + R and clean the fuel tank |
| 13 | Check that the high pressure pump operates correctly | All OK | Problems encountered | Operation |
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| Replace the high pressure pump Op. 1060E10 DIESEL INJECTION PRESSURE PUMP - R.R. and check that the fault is no longer present. | End of diagnosis. | The fault persists. | Move on to Step 14. |
| 14 | Check that the engine management control unit operates correctly | All OK | Problems encountered | Operation |
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| Check that the engine control unit is working properly. | End of diagnosis. | Engine control unit defective | Replace the engine control unit. Op. 1060G80 DIESEL ELECTRONIC INJECTION CONTROL UNIT - R.R |